U.S. patent application number 12/860536 was filed with the patent office on 2010-12-16 for automotive structural joint and method of making same.
This patent application is currently assigned to UNITED STATES COUNCIL FOR AUTOMOTIVE RESEARCH. Invention is credited to Erik Arthur Banks, Elisabeth Jane Berger, John D. Fickes, John P. Fuchs.
Application Number | 20100314909 12/860536 |
Document ID | / |
Family ID | 41266259 |
Filed Date | 2010-12-16 |
United States Patent
Application |
20100314909 |
Kind Code |
A1 |
Fuchs; John P. ; et
al. |
December 16, 2010 |
AUTOMOTIVE STRUCTURAL JOINT AND METHOD OF MAKING SAME
Abstract
A joint for an automotive vehicle may be formed by applying an
adhesive to at least one of a first member and a first surface of a
composite member, placing the first member in contact with the
first surface of the composite member, applying an adhesive to at
least one of a second member and a second surface of the composite
member, positioning a divot portion of the second member within an
aperture of the composite member, placing the second member in
contact with the second surface of the composite member, attaching
the divot portion of the second member with the first member and
curing the adhesives.
Inventors: |
Fuchs; John P.; (Farmington,
MI) ; Fickes; John D.; (Brighton, MI) ; Banks;
Erik Arthur; (Dearborn, MI) ; Berger; Elisabeth
Jane; (Farmington Hills, MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C.
1000 TOWN CENTER, TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075
US
|
Assignee: |
UNITED STATES COUNCIL FOR
AUTOMOTIVE RESEARCH
Southfield
MI
United States Automotive Materials Partnership, LLC
Southfield
MI
|
Family ID: |
41266259 |
Appl. No.: |
12/860536 |
Filed: |
August 20, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12119084 |
May 12, 2008 |
7819452 |
|
|
12860536 |
|
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|
|
Current U.S.
Class: |
296/191 ;
156/60 |
Current CPC
Class: |
B29C 66/1122 20130101;
Y10T 156/10 20150115; B29C 65/5057 20130101; B29C 66/71 20130101;
B29C 66/742 20130101; B29K 2305/12 20130101; B29C 66/721 20130101;
B29C 66/7394 20130101; B23K 11/11 20130101; B29K 2305/02 20130101;
B29C 65/483 20130101; B29K 2101/10 20130101; B29K 2309/08 20130101;
B29C 65/485 20130101; B29K 2101/12 20130101; B29C 65/4835 20130101;
B23K 11/16 20130101; B29L 2031/3002 20130101; B29C 65/5021
20130101; B29C 65/4845 20130101; B29C 66/474 20130101; B29C 66/21
20130101; B29C 65/4825 20130101; B29C 66/7392 20130101; B29L
2031/3055 20130101; B29C 66/71 20130101; B29C 66/5326 20130101;
B29K 2105/06 20130101; B29C 66/472 20130101; B29C 65/562 20130101;
F16B 11/006 20130101; B29C 66/112 20130101; B29C 66/131 20130101;
B29C 66/304 20130101; B62D 29/048 20130101; B23K 2101/006 20180801;
B29C 66/7212 20130101; B29C 66/7212 20130101; B29K 2307/00
20130101; B29K 2067/00 20130101; B29K 2309/08 20130101 |
Class at
Publication: |
296/191 ;
156/60 |
International
Class: |
B62D 29/00 20060101
B62D029/00; B32B 37/12 20060101 B32B037/12 |
Claims
1. A method of forming a structural joint for an automotive
vehicle, the method comprising: applying an adhesive to at least
one of a first member and a first surface of a composite member;
placing the first member in contact with the first surface of the
composite member; applying an adhesive to at least one of a second
member and a second surface of the composite member opposite the
first surface; positioning a divot portion of the second member
within an aperture of the composite member; placing the second
member in contact with the second surface of the composite member;
attaching the divot portion of the second member with the first
member; and curing the adhesives thereby forming a structural
joint.
2. The method of claim 1 wherein attaching the divot portion of the
second member with the first member includes welding the divot
portion of the second member with the first member.
3. A structural member for an automotive vehicle comprising: a
composite panel having opposing sides and a surface defining an
aperture therethrough; and first and second metal panels
respectively adhesively bonded to the opposing sides of the
composite panel, the first and second metal panels each including a
button formed thereon, the buttons each extending into the aperture
and being attached together.
4. The structural member of claim 3 wherein the buttons are welded
together.
5. The structural member of claim 3 wherein the buttons are
mechanically fastened together.
6. The structural member of claim 3 wherein the composite panel is
sandwiched between the first and second metal panels.
7. The structural member of claim 3 wherein at least one of the
buttons has a square shape.
8. The structural member of claim 3 wherein the aperture is round.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. application Ser.
No. 12/119,084, filed May 12, 2008, which is hereby incorporated by
reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] The invention relates to automotive structural joints and
methods of making the same.
[0004] 2. Discussion
[0005] Certain structural panels and joints are known. As an
example, U.S. Pat. No. 3,256,669 to Seiwert discloses a reinforced
metal panel assembly made by using a pair of metal panels and an
intermediate core of suitable material such as plywood, balsa,
Masonite, wall-board, aluminum or any of the other light metals.
The panels are joined to produce a compressive interference fit
between the panels and the core. The metal panels may be designated
as an inner and an outer panel depending on their intended position
in a finished structure.
[0006] As another example, U.S. Pat. No. 4,791,765 to Noggle
discloses a synthetic material structural body panel comprising a
synthetic material. An aperture extends through the synthetic
material panel. A metal attachment plate fixedly engages the
synthetic material and spans the aperture. Noggle also discloses a
joint between the synthetic material structural body panel and
another structural body panel. The joint comprises a metal
attachment plate as described above and means, such as spot
welding, for securing the metal attachment plate to the other
structural body panel.
[0007] As yet another example, U.S. Pat. No. 6,291,792 to
Fussnegger et al. discloses a welded joint made between a
sheet-steel component and a sheet-aluminum component by way of a
lap or web weld. Hat-like clip parts are pushed through openings in
the sheet-aluminum component. The clip parts are welded at their
bottom to the sheet-steel component and overlap an exposed flat
side of the sheet-aluminum component with their flanges. An
adhesive is introduced into a gap situated between the clip part
and the sheet-aluminum component.
SUMMARY
[0008] A joint for an automotive vehicle may comprise a composite
member having opposing surfaces and including an aperture extending
therethrough and a first metal member positioned adjacent to one of
the opposing surfaces of the composite member. The joint may also
include a second metal member positioned adjacent to the other of
the opposing surfaces of the composite member. The second metal
member includes a portion extending into the aperture of the
composite member. The portion extending into the aperture is
fixedly attached with the first metal member. The joint may further
include a first uncured adhesive layer disposed between one of (i)
the first metal member and the one of the opposing surfaces of the
composite member and (ii) the second metal member and the other of
the opposing surfaces of the composite member.
[0009] A structural member for an automotive vehicle may include a
composite panel having opposing sides and a surface defining an
aperture therethrough. The structural member may also include first
and second metal panels respectively adhesively bonded to the
opposing sides of the composite panel. The first and second metal
panels each include a button formed thereon. The buttons each
extend into the aperture and are attached together.
[0010] A structural joint for an automotive vehicle may comprise a
composite member having opposing surfaces and including an aperture
extending therethrough, a first member adhered with one of the
opposing surfaces of the composite member and a second member
adhered with the other of the opposing surfaces. The second member
includes a portion extending into the aperture of the composite
member. The portion extending into the aperture is fixedly attached
with the first member.
[0011] A method of forming a structural joint for an automotive
vehicle may include applying an adhesive to at least one of a first
member and a first surface of a composite member, placing the first
member in contact with the first surface of the composite member
and applying an adhesive to at least one of a second member and a
second surface of the composite member opposite the first surface.
The method may also include positioning a divot portion of the
second member within an aperture of the composite member, placing
the second member in contact with the second surface of the
composite member, attaching the divot portion of the second member
with the first member and curing the adhesives.
[0012] While example embodiments in accordance with the invention
are illustrated and disclosed, such disclosure should not be
construed to limit the claims. It is anticipated that various
modifications and alternative designs may be made without departing
from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an embodiment of a portion
of an automotive structural joint.
[0014] FIG. 2A is an exploded view, in cross-section, of the
automotive structural joint of FIG. 1.
[0015] FIG. 2B is an assembly view, in cross-section, of the
automotive structural joint of FIG. 1.
DETAILED DESCRIPTION
[0016] Referring now to FIG. 1, a composite member 10 is sandwiched
between members 12, 14 to form a structural joint 16. The composite
member 10 may comprise any synthetic material suitable for use as a
structural member for an automotive vehicle. For example, the
composite member 10 may comprise a non-reinforced or
fiber-reinforced thermoplastic and/or a thermoset plastic. The
material comprising the composite member 10 may be selected based
on the particular application for which it is intended. Suitable
commercially available fibers include glass fibers, carbon fibers,
etc. and any combination thereof. Of course, other suitable
materials may be used.
[0017] The members 12, 14 may comprise any suitable metal, e.g.,
steel, aluminum, etc., for use in automotive applications. For
example, the member 12 may comprise a steel doubling plate and the
member 14 may comprise a structural steel rail configured to act as
a load bearing member of a vehicle body.
[0018] The composite member 10 of a chosen synthetic material may
be formed or shaped into the desired configuration using any
suitable technique. Such suitable techniques include injection
molding, resin transfer molding and compression molding. The
technique used may depend on the material employed. For example,
compression molding techniques may be applied to sheet molding
compounds (SMC) including a fiber-reinforced thermoset
polyester.
[0019] In the embodiment of FIG. 1, buttons 18, e.g., divots,
depressions, etc., are provided in the member 12 and extend into
respective apertures 20 in the composite member 10. The buttons 18
may be stamped or otherwise integrally formed with the member 12.
In other embodiments, the buttons 18 may be provided in the member
14 in addition to, or instead of, the member 12. In certain of
these embodiments, some of the buttons 18 provided in the members
12, 14 may extend into the same apertures 20 (and, for example,
meet in a middle of the apertures 20) while other of the buttons 18
may extend into different apertures 20. For example, the buttons 18
provided in the members 12, 14 may extend into every other of the
apertures 20 in an alternating fashion. Of course, other
configurations are also possible.
[0020] The buttons 18 of FIG. 1 are sized relative to the apertures
20 so as to provide a clearance fit. In other embodiments, the
buttons 18 may be sized relative to the apertures 20 so as to
provide an interference fit.
[0021] The structural joint 16 illustrated in FIG. 1 includes three
buttons positioned generally along an axis, A. Of course, a greater
or fewer number of the buttons 18 may be used. In other
embodiments, the buttons 18 may be positioned to form a grid or
other desired pattern/layout.
[0022] In some embodiments, a portion of each of the buttons 18
contact and are welded, as discussed below, to the member 14. In
other embodiments, the buttons 18 may be riveted, bolted or
otherwise mechanically fastened to the member 14. Additionally, the
buttons 18 (and the apertures 20) may be of sufficient size so as
to permit several welds per button 18.
[0023] The buttons 18 may be formed so that portions of the member
12 lie flush against the composite member 10. For example, the
buttons 18 may have a depth approximately equal to the thickness of
the composite member 10. The buttons 18 may also be formed so that
portions of the member 12 are spaced away from the composite member
10. For example, the buttons 18 may have a depth that is greater
than the thickness of the composite member 10. Other configurations
and arrangements are also possible.
[0024] The apertures 20 may be formed during the initial
manufacture of the composite member 10. For example, the apertures
20 may be cut into the composite member 10 or may be provided by
appropriate design of the tooling used in molding the composite
member 10.
[0025] The apertures 20 of FIG. 1 have a shape complimentary to the
buttons 18. In other embodiments, the apertures 20 may, for
example, have a shape non-complimentary to the buttons 18. For
example, the apertures 20 may have a square shape and the buttons
18 may have a conical shape.
[0026] As discussed below, the members 12, 14 are bonded with the
composite member 10 so as to span, e.g., cover, the apertures 20 of
the composite member 10. The buttons 18 of
[0027] FIG. 1 engage the apertures 20 to, inter alia, locate the
member 12 relative to the composite member 10. When the members 12,
14 are attached with the composite member 10, at least a portion of
the composite member 10 surrounding the apertures 20 is sandwiched
between the members 12, 14. The members 12, 14 may be adhesively
bonded, as discussed below, or otherwise fixedly engaged with the
composite member 10 so as to cover the apertures 20.
[0028] Adhesives for bonding the members 12, 14 with the composite
member 10 may include an epoxy, urethane, acrylic, etc., applied,
for example, as a tape, liquid, paste or pressure sensitive
adhesive. Any suitable adhesive, however, may be used. The
selection of a suitable adhesive may depend on the material
comprising the composite member 10, the cost of the adhesive, ease
of processing the adhesive, the intended use of the structural
joint 16, etc. The adhesives may be cured by heat, room-temperature
chemical reaction, induction or any other curing method.
[0029] In some embodiments, gaps between the members 10, 12 and 10,
14 may be determined by glass beads, wires, stand-offs on any of
the members 10, 12, 14, assembly fixturing, etc.
[0030] As apparent to those of ordinary skill, the composite member
10 and the members 12, 14 may have any configuration suitable for
the environment and/or intended use of the structural joint 16. For
example, in embodiments where the member 14 is curved, the
composite member 10 and member 12 may also be formed with
corresponding curves to mate with the member 14. Likewise, the
apertures 20 and buttons 18 may have any suitable configuration for
the environment and/or intended use of the structural joint 16. For
example, the apertures 20 may have a triangular, square or other
suitable shape. Similarly, the buttons 18 may have a mating
triangular, square or other suitable shape similar or dissimilar to
the shape of the apertures 20. Referring now to FIGS. 2A and 2B,
the following may be performed to assemble the structural joint 16.
An adhesive layer 22 is applied to one or both of the composite
member 10 and the member 14. The member 14 is then placed in
contact with the composite member 10. An adhesive layer 24 is
applied to one or both of the composite member 10 and the member
12. The member 12 is positioned relative to the composite member 10
such that the button 18 is in registration with the aperture 20.
The member 12 is then placed in contact with the composite member
10. The button 18 is fixedly attached, e.g., spot welded, with the
member 14 at weld 26. The adhesive layers 22, 24 are then cured to
bond the composite member 10 with the members 12, 14. Because the
button 18 is fixedly attached with the member 14 prior to curing,
there is no need for fixturing or other machinery to hold the
members 12, 14 in place relative to one another during the curing
process.
[0031] In other embodiments, the adhesive layer 24 may first be
applied to one or both of the composite member 10 and the member
12. The member 12 may then be positioned relative to the composite
member 10 such that the button 18 is in registration with the
aperture 20. The member 12 may then be placed in contact with the
composite member 10. The adhesive layer 22 may next be applied to
one or both of the composite member 10 and the member 14. The
member 14 may then be placed in contact with the composite member
10. Welding, for example, of the button 18 with the structural
member 14 and curing of the adhesive layers 22, 24 may follow. In
still other embodiments, the adhesive layers 22, 24 may be applied
at the same time, etc., prior to fixedly attaching and curing.
Alternatively, a single adhesive layer may also be applied prior to
fixedly attaching and curing.
[0032] The structural joint 16 may be used in a variety of
applications. For example, the structural joint 16 may be used to
join a composite floorpan of an automotive vehicle to a steel frame
rail, dash-panel and rear floor of the vehicle. The structural
joint 16 may also be used to join a composite hood inner panel of
an automotive vehicle to steel hinge reinforcements of the vehicle,
etc.
[0033] While only certain embodiments of the invention have been
illustrated and described, it is not intended that these
embodiments illustrate and describe all possible forms of the
invention. Rather, the words used in the specification are words of
description rather than limitation, and it is understood that
various changes may be made without departing from the spirit and
scope of the invention.
* * * * *